Hybrid opposed-piston engine system

ABSTRACT

An opposed-piston engine system equipped for full hybrid compressed-air/combustion includes capacity for storing air compressed by the engine during a combustion mode of operation. The hybrid opposed-piston engine system includes a control mechanization for operating the opposed-piston engine in a combustion mode by provision of fuel, in a compressed-air mode by provision of stored compressed air, and in a combustion mode supplemented by provision of stored compressed air. A method of operating a hybrid vehicle equipped with an opposed-piston engine includes storing air compressed by the engine during a combustion mode of operation and operating in the vehicle a compressed-air mode by provision of stored compressed air.

PRIORITY

This application claims priority to the provisional application forpatent which has been filed in the United States Patent and TrademarkOffice on 27 Feb. 2015, U.S. Ser. No. 62/126,163.

RELATED APPLICATIONS

This application contains subject matter related to the subject matterof: U.S. patent application Ser. No. 13/373,448, filed Nov. 14, 2011,published as US 2012/0125298 A1 on May 24, 2012, now U.S. Pat. No.8,746,190 B2; U.S. patent application Ser. No. 13/385,510, filed Feb.21, 2012, published as US 2012/0210985 A1 on Aug. 23, 2012, now U.S.Pat. No. 8,919,304 B2; and U.S. patent application Ser. No. 14/550,813,filed Nov. 21, 2014, now U.S. Pat. No. 8,997,712 B2.

FIELD

The field is hybrid opposed-piston internal combustion engine systems.More specifically, the field covers hybrid opposed-piston internalcombustion engine systems that provide motive power for vehicles.

BACKGROUND

When compared with four-stroke engines, ported, two-stroke,opposed-piston internal combustion engines have acknowledged advantagesof specific output, power density, and power-to-weight ratio. For theseand other reasons, after almost a century of limited use, increasingattention is being given to the utilization of opposed-piston enginesfor motive power in a wide variety of modern vehicles.

Per FIG. 1 an opposed-piston, two-stroke engine 8 includes at least onecylinder 10 with a bore 12 and longitudinally displaced intake andexhaust ports 14 and 16 machined or formed in the cylinder, nearrespective ends thereof. Each of the intake and exhaust ports includesone or more circumferential arrays of openings in which adjacentopenings are separated by a solid portion of the cylinder wall (alsocalled a “bridge”). In some descriptions, each opening is referred to asa “port”; however, the construction of a circumferential array of such“ports” is no different than the port constructions in FIG. 1. Fuelinjection nozzles 17 are secured in threaded holes that open through thesidewall of the cylinder. Two pistons 20, 22 are disposed in the bore 12with their end surfaces 20 e, 22 e in opposition to each other. Forconvenience, the piston 20 is referred to as the “intake” piston becauseof its proximity to the intake port 14. Similarly, the piston 22 isreferred to as the “exhaust” piston because of its proximity to theexhaust port 16. Preferably, but not necessarily, the intake piston 20and all other intake pistons are coupled to a crankshaft 30 disposedalong one side of the engine 8, and the exhaust piston 22 and all otherexhaust pistons are coupled to a crankshaft 32 disposed along theopposite side of the engine 8. A gear train (not shown) couples thecrankshafts and includes an output shaft that provides motive power todrive a vehicle. Other representative opposed-piston engineconstructions are described in U.S. Pat. No. 1,683,040; U.S. Pat. No.2,031,318; U.S. Pat. No. 8,485,161 B2; and U.S. Pat. No. 8,539,918 B2.

During operation of a two-stroke, opposed-piston engine, such as theengine 8 of FIG. 1, pairs of pistons move in opposition in the bores ofported cylinders such as the cylinder 10. In a compression stroke, astwo opposed pistons move toward each other in a cylinder bore, acombustion chamber is formed in the bore, between the end surfaces ofthe pistons. Fuel is injected directly into the volume of the combustionchamber when the pistons are at or near respective top center (“TC”)locations in the bore. The fuel is injected through fuel injectornozzles mounted on the sidewall of the cylinder. The fuel mixes with airadmitted into the bore. As the air-fuel mixture is compressed betweenthe piston end surfaces, the compressed air reaches a temperature thatcauses the fuel to ignite. Combustion follows. Combustion timing isfrequently referenced to “minimum volume” of the combustion chamber,which occurs when the piston end surfaces are in closest mutualproximity. In some instances injection occurs at or near minimum volume;in other instances, injection may occur before minimum volume. In anycase, in response to combustion the pistons reverse direction andundergo a power stroke. During the power stroke, the pistons move awayfrom each other toward bottom center (“BC”) locations in the bore. Asthe pistons reciprocate between top and bottom center locations theyopen and close ports formed in respective intake and exhaust locationsof the cylinder in timed sequences that control the flow of air into,and exhaust from, the cylinder.

The related applications describe recent improvements to opposed-pistonengines which incorporate compression-release functionality intoconstruction and operation of the engines. In this regard, compressionrelease functionality involves the release of compressed air from acylinder other than through its exhaust port and in the absence ofcombustion. One example is compression-release braking.Compression-release braking is a particularly useful feature forvehicles such as medium-duty and heavy-duty trucks because it usesengine operations to slow vehicle speed instead of (or in addition to)friction brakes. The designs for compression-release braking foropposed-piston engines involve the exhaustion of compressed air frombetween the piston end surfaces while fuel injection is suppressed. Workperformed in transporting and compressing the air is not returned to thecrankshafts, thereby slowing the engine, which slows the vehicle. Thecompressed air is released by way of a valve acting through the side ofthe cylinder at a location between the intake and exhaust ports of thecylinder. As taught in U.S. Pat. No. 8,746,190 B1, the releasedcompressed air can be stored in an accumulator and released therefrom tosupplement work performed by various engine components during normalengine operation.

As the designs for opposed-piston internal combustion engines advanceand lead to improved performance with engine configurations, the returnsof investment will begin to diminish. It is therefore useful anddesirable to consider hybridization of opposed-piston engine systems byincorporation of stored energy that can be activated during engineoperation to supplement the work enabled by internal combustion alone,which will introduce a new factor to increase the engine's efficiency.The rewards of such hybridization would be increased to the extent thatthe stored energy could be replenished by the engine during operation.

One hybrid engine system that has been proposed for vehicle use may bedescribed as an air/gasoline hybrid in which compressed air is generatedand stored during unassisted gasoline operation and then released toassist gasoline operation of the engine or to power the engine solelywith air. (Hybrid Air An innovative petrol full-hybrid solution PSAPEUGEOT CITROEN Press Release Jan. 22, 2013). It would be beneficial interms of improved performance to consider the hybridization ofopposed-piston engine systems by combining pneumatic and combustioncapabilities to power the engines.

The compression-release braking constructions and the air storage andrelease capability described in related U.S. Pat. No. 8,746,190 B1 arecombined to enable valve-controlled operation for transporting storedcompressed air from an accumulator into a channel through which air isprovided to the intake ports of the opposed-piston engine. The provisionof compressed air may, for example, supplement work performed by asupercharger during normal combustion operation, thereby improving fuelconsumption. This engine system performs as a mild hybrid with two modesof operation: combined compressed-air/combustion and combustion alone.However, without the capability of operating the engine in acompressed-air-only mode, the full hybrid potential is unrealized.

SUMMARY

In the mild hybrid opposed-piston engine system configuration, acompressed-air storage device receives compressed air from the cylinderthrough a unidirectional channel controlled by a compression releasevalve. According to this disclosure, the full hybrid potential for acompressed-air/combustion opposed-piston engine system is realized byprovision of a valve-controlled bidirectional channel between thecompressed-air storage device and the cylinder that supportsbidirectional transport of compressed air to and from the cylinder byway of the compression release valve.

Another valve-controlled channel allows for transport of compressed airfrom the air storage device to the engine's charge air channel, which,together with the bidirectional transport channel between thecompressed-air storage device and the cylinder, underpins a full hybridcapability for the opposed-piston engine.

In some aspects, another valve-controlled channel may be provided toprovide transport of compressed air from the cylinder forcompression-release engine braking.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic illustration of an opposed-piston engine of theprior art.

FIG. 2 is a schematic illustration of a hybrid opposed-piston enginesystem according to this disclosure.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The hybrid opposed-piston engine system described in this specificationis presented in an explanatory context that includes a two-stroke,fuel-injected opposed-piston engine having at least one cylinder with abore in which a pair of pistons is disposed with their end surfaces inopposition. This example is not intended to limit the opposed-pistonengine in any way. Thus, a hybrid opposed-piston engine system is notlimited to any specific number of crankshafts. For example, the enginemay comprise one crankshaft, two crankshafts, or three or morecrankshafts. In other aspects, the hybrid opposed-piston engine maycomprise one, two, three, or more ported cylinders, each with a bore,piston-controlled exhaust and intake ports, and a pair of opposedpistons disposed in the bore.

In this specification the oxygen-bearing gas mixture provided to mixwith fuel in order to enable combustion in an opposed-piston engine isreferred to as “air”, and this term is intended to include fresh airand/or charge air. In some instances, the air may include an admixtureof exhaust products; otherwise, it may not.

In FIG. 2, a hybrid opposed-piston engine system which may be used forpowering a vehicle includes an opposed-piston engine 49 having one ormore cylinders 50. Each cylinder 50 has a bore 52 and intake and exhaustports 54 and 56 formed or machined in respective ends of the cylinder.Intake and exhaust pistons 60 and 62 are slidably disposed in the bore52 with their end surfaces 60 e and 62 e opposing one another. When thepistons 60 and 62 are at or near their TC positions, a combustionchamber is defined by the bore 52 and the end surfaces of the pistons.The intake piston 60 and all other intake pistons are coupled to acrankshaft 70 disposed along one side of the engine 49, and the exhaustpiston 62 and all other exhaust pistons are coupled to a crankshaft 72disposed along the opposite side of the engine. Fuel is injecteddirectly into the combustion chamber, between the piston end surfaces 60e and 62 e, through at least one fuel injector nozzle 74 mounted in anopening through the side of the cylinder 50; preferably, a second fuelinjector (not seen) is mounted to an opening in the cylinder oppositethe opening in which the injector 74 is mounted. A fuel supply 76comprising a reservoir, a pump or pumps, and a common rail or railssupplies fuel to the injectors of the engine.

The engine 49 operates in a combustion mode as per the description ofthe engine illustrated in FIG. 1. In this regard, air is transportedthrough a charge air channel 88 of the engine to the intake port 54 whenthe pistons 60 and 62 are near BC. The air flows through the intake port54 into the bore 52 of the cylinder. As rotation of the crankshafts 70and 72 drives the pistons into the bore, the air is compressed into thespace of the combustion chamber and mixed with fuel injected into thecombustion chamber. The air/fuel mixture combusts, which forces thepistons apart and thereby delivers mechanical energy to the crankshafts.When the pistons are near BC, products of combustion (exhaust) flow outof the exhaust port into and through an exhaust channel 78 of theengine.

For full hybrid capability, the opposed-piston engine system of FIG. 2is also equipped to operate the engine 49 in one or more compressed-airmodes. In this regard, the engine system has a bidirectional airtransport channel for transporting compressed air through acompression-release port 81 that opens through the sidewall of thecylinder 50 at a position intermediate the intake and exhaust ports;preferably, but not necessarily, the port 81 is located in a portion ofthe cylinder between the TC locations of the pistons 60 and 62. Thebidirectional air transport channel includes a compression-release valve80 mounted in the compression release port 81, a transport channel 82 influid communication with the compression-release valve 80, and a storagevalve 84 in fluid communication with the transport channel 82. A channel85 transports compressed air between the storage valve 84 and acompressed air storage device 86. Alternatively, the storage valve maybe mounted on the device 86. A channel 87 transports compressed air fromthe storage valve 84 to an intake valve assembly 90. Pressurized air isprovided as an input to the intake valve assembly 90. The intake valveassembly 90 has an output that is transported to the engine intake portsvia channel 88.

The valves 80, 84, and 90 are preferably high-speed, computer-controlleddevices actuated by any one or more of mechanical, electrical,hydraulic, and pneumatic means. Control of these devices and of the fuelsupply 76 is implemented by a programmed engine control unit (ECU) 100.The ECU 100 receives input data relative to the operating state of theengine (Engine OP State) and also receives sensed engine parametersincluding, without limitation, a crank angle (CA) indicative of enginespeed and operating condition, Air Storage Pressure (P1) indicative ofthe air pressure in the air storage device 86, and cylinder Pressure(P2) indicative of the gas pressure in the cylinder, between the endsurfaces of the pistons 60 and 62. In instances when the system of FIG.2 provides motive power in a vehicle, the ECU 100 receives input datarelative to the positions of Accelerator and Brake Pedals. The sensorsby which the ECU 100 receives these parameter values are not shown inthe figures; however, for purposes of this specification these and othersensors may comprise physical measurement devices and/or virtualsystems, Using these and possibly other parameters, the ECU may beprogrammed to cause the valve setting configurations set out in Table I.

TABLE I Valve Setting 1 Setting 2 Setting 3 80 Shut bore 52 to shutchannel 82 84 Shut air storage 86 air storage 86 to channel 82 tochannel 87 90 Shut shut channel 87 to channel 88

Responsive to sensed parameter values and an indicated engine state, thehybrid opposed-piston engine system of FIG. 2 may be configured for openbi-directional fluid communication between the air storage device 86 andthe cylinder bore 52 when the valves 80, 84, and 90 are set to setting2. Depending on the difference in air storage and cylinder pressure, thebidirectional configuration supports either replenishment of storedcompressed air by flow of compressed air from the cylinder 50 into theair storage device 86 or air-only operation of the engine 49 by movementof the pistons 60 and 62 in response to flow of stored compressed airfrom the air storage device 86 into the cylinder 50.

Responsive to sensed parameter values and an indicated engine state, thehybrid opposed-piston engine of FIG. 2 may be configured forsupplementing combustion operation of the engine when the valves 80, 84,and 90 are set to setting 3, which enables flow of stored compressed airfrom the air storage device 86 into the charge air channel via the flowpath 86, 85, 84, 90.

In some aspects, the engine system of FIG. 2 may further be equipped forcompression-release engine braking by provision of a braking valve 92,also under control of the ECU 100. The braking valve 92 is connected tothe transport channel 82 so as to release compressed air from thecylinder 50 for the purpose of engine braking. Preferably, but notnecessarily, the compressed air released for engine braking istransported by the braking valve 92 to the exhaust channel 78.Accordingly, responsive to sensed parameter values and a sensed enginestate, the ECU 100 may be programmed to configure the engine for enginebraking by opening the compression-release valve 80, shutting thestorage valve 84, and opening the braking valve 92 so that compressedair is released from the cylinder 50 via the flow path 82, 92.

As will be appreciated when FIG. 2 is considered, a full hybridcompressed-air/combustion capability of an opposed-piston engine systemis realized by provision of a bidirectional air flow path between acompressed-air storage device and the bore of at least one portedcylinder.

A method of operating a wheeled vehicle such as an automobile, truck, ormotorcycle, or a tracked vehicle such as a tank or snowmobile, equippedwith a hybrid compressed-air/combustion opposed-piston engine systemaccording to FIG. 2 (hereinafter, a “hybrid vehicle”) may include aprocess for storing compressed air for later use and a process foroperating the engine using compressed air alone. In either or bothcases, the ECU 100 is programmed to execute processes in which aircompressed between the pistons is stored in the air storage device andin which the opposed-piston engine is driven by compressed air, alone orto supplement combustion. In some aspects, the ECU 100 is furtherprogrammed to execute a process for braking the engine by release ofcompressed air.

Energy may be stored as compressed air in the air storage device 86during a braking or deceleration event of the hybrid vehicle by way of aprocess in which:

-   -   1. The ECU 100 detects from brake and/or throttle pedal position        signals that the vehicle is decelerating;    -   2. The ECU 100 shuts off fuel at one or more injectors 70 and        lowers rail pressure;    -   3. When the cylinder pressure P₂ exceeds the air storage        pressure P₁, the ECU 100 opens the decompression valve 80 and        uses the storage valve 84 to connect the released air directly        into the air storage device 86;    -   4. When the cylinder pressure P₂ drops below the air storage P₁,        the ECU 100 closes the compression-release valve 80 to prevent        loss of compressed air from the air storage device 86.    -   5. When the air storage device 86 is filled to its capacity, the        ECU 100 again opens the compression release valve 80 but uses        the braking valve 92 to output the released air.    -   6. Comment: //If the air intake pressure is controlled by a        supercharger with a typical compression ratio of 16 to 17, it is        possible to reach the air storage device capacity limit//    -   7. At the end of the braking or deceleration event, fuel        injection is resumed. The storage valve 84 can be closed to        prevent leakage from the air storage device 86.

On a subsequent launch event (acceleration, for example), compressed airstored in the device 86 may be used to convert this stored energy intomechanical energy for propelling the hybrid vehicle by way of a processin which:

-   -   1. The ECU 100 detects from brake and throttle pedal positions        that the vehicle is accelerating;    -   2. When the ECU recognizes from the crank angle CA that the two        pistons 60 and 62 are at their minimum volume positions, it        ceases delivery of fuel to one or more injectors 70 and sets the        storage valve 84 to directly connect the air storage device 86        to the compression-release valve 80;    -   3. The compression-release valve 80 is then opened, thereby        releasing stored compressed air from the air storage device 86        and injecting the released compressed air into the cylinder bore        52 through the compression-release port 81 to force the pistons        apart thereby providing positive torque at the output shaft of        the engine;    -   4. When the cylinder pressure P₂ drops below the air storage        pressure P₁, the ECU 100 closes the compression-release valve        80; and    -   5. When the ECU 100 determines based on cylinder and tank        pressures P₂ and P₁ that the remaining energy is insufficient to        provide the desired launch acceleration rate, it can then begin        normal fueled operation.

In addition, if desired for a quicker launch transient, the storagevalve 84 can be set to directly connect to the air storage tank throughthe normally closed intake valve 90, and the intake valve 90 can beopened, thereby supplementing the intake air with compressed airreleased from the air storage device 86.

Although principles of compressed-air/combustion hybridization ofopposed-piston engines have been described with reference to presentlypreferred embodiments, it should be understood that variousmodifications can be made without departing from the spirit of thedescribed principles. Accordingly, the scope of patent protectionaccorded to these principles is limited only by the following claims.

The invention claimed is:
 1. A hybrid engine system; comprising: anopposed-piston engine with at least one cylinder havingpiston-controlled exhaust and intake ports, a charge air channel toprovide air to at least one intake port, an exhaust channel to removeexhaust gas from at least one exhaust port, a fuel system to deliverfuel for combustion in the cylinder; and a compression-release port influid communication with the cylinder bore; an air storage device; abidirectional air transport channel connecting the air storage devicewith the compression release port, the bidirectional air transportchannel comprising a braking valve connected to the bidirectional airtransport channel; and, an engine control unit programmed to cause thebidirectional air transport channel to transport compressed air betweenthe air storage device and the compression release port and furtherprogrammed to cause the braking valve to couple the bidirectional airtransport channel to the exhaust channel to either store compressed airin the air storage device or inject compressed air between the pistons.2. The hybrid engine system of claim 1; in which the bidirectional airtransport channel comprises a compression-release valve mounted in thecompression release port, a transport channel in fluid communicationwith the compression-release valve, and a storage valve in fluidcommunication with the transport channel and connected to the airstorage device.
 3. The hybrid engine system of claim 2, in which thestorage valve is further connected to the charge air channel and theengine control unit is further programmed to cause the storage valve tocouple the air storage device to the charge air channel.
 4. The hybridengine system of claim 1, in which the opposed-piston engine is atwo-stroke, fuel-injected opposed-piston engine.
 5. The hybrid enginesystem of claim 1, in which the opposed-piston engine includes one, two,or three or more crankshafts.
 6. The hybrid engine system of claim 1, inwhich the opposed-piston engine includes one, two, or three or moreported cylinders.
 7. The hybrid engine system of claim 6, in which theopposed-piston engine is a two-stroke, fuel-injected opposed-pistonengine.
 8. The hybrid engine system of claim 7, in which theopposed-piston engine includes one, two, or three or more crankshafts.9. A hybrid engine system, comprising: an opposed-piston engine with atleast one cylinder having piston-controlled exhaust and intake ports, acharge air channel to provide air to at least one intake port, anexhaust channel to remove exhaust gas from at least one exhaust port, afuel system to deliver fuel for combustion in the cylinder, and acompression-release port in fluid communication with the cylinder bore;an air storage device; a bidirectional air transport channel connectingthe air storage device with the compression release port; and, an enginecontrol unit programmed to cause the bidirectional air transport channelto transport compressed air between the air storage device and thecompression release port to either store compressed air in the airstorage device or inject compressed air between the pistons, wherein thebidirectional air transport channel comprises a compression-releasevalve mounted in the compression release port, a transport channel influid communication with the compression-release valve, and a storagevalve in fluid communication with the transport channel and connected tothe air storage device.
 10. The hybrid engine system of claim 9, inwhich the storage valve is further connected to the charge air channeland the engine control unit is further programmed to cause the storagevalve to couple the air storage device to the charge air channel. 11.The hybrid engine system of claim 9, in which the opposed-piston engineis a two-stroke, fuel-injected opposed-piston engine.
 12. The hybridengine system of claim 9, in which the opposed-piston engine includesone, two, or three or more crankshafts.
 13. The hybrid engine system ofclaim 9, in which the opposed-piston engine includes one, two, or threeor more ported cylinders.
 14. The hybrid engine system of claim 13, inwhich the opposed-piston engine is a two-stroke, fuel-injectedopposed-piston engine.
 15. The hybrid engine system of claim 14, inwhich the opposed-piston engine includes one, two, or three or morecrankshafts.